Multiple bed downflow reactor

ABSTRACT

The invention relates to a multiple bed downflow reactor comprising vertically spaced apart reaction beds, preferably beds of catalyst particles, and, between adjacent beds, a mixing device for mixing fluids, the mixing device comprising:
         (i) a substantially horizontal collection tray,   (ii) a swirl chamber for mixing liquid arranged below the collection tray, having an upper end part that is in direct fluid communication with the upper surface of the collection tray and an outlet opening at its lower end, and   (iii) a substantially horizontal distribution tray located below the swirl chamber, which distribution tray is provided with a plurality of openings or downcomers for downward flow of liquid and gas, in which reactor each reaction bed rests upon a support tray provided with a central opening and which reactor further comprises open-ended pipes extending through each central opening such that a vertical chute is formed from the reaction bed above the mixing device to the reaction bed below the mixing device, wherein the swirl chamber of the mixing device is arranged around the open-ended pipe.       

     The invention further relates to the use of such a reactor in hydrocarbon processing.

The present invention relates to a multiple bed downflow reactor comprising a mixing device for mixing fluids and to the use of such a reactor in hydrocarbon processing.

A multiple-bed downflow reactor is a reactor in which gas and liquid flow co-currently downward through a number of reaction beds arranged one below the other. Such reactors are used in the chemical and petroleum refining industries for effecting various processes such as catalytic dewaxing, hydrotreating and hydrocracking. In these processes a liquid phase is typically mixed with a gas phase and the mixed fluids are passed over a particulate catalyst maintained in the reaction beds.

As the fluids pass concurrently through a reaction bed, the distribution of liquid and gas across the reaction bed will tend to become uneven with adverse consequences with regard to the extent of reaction and also temperature distribution. In order to achieve a uniform distribution of liquid and gas and of temperature in the fluids entering the next lower reaction bed, a fluid mixing device, of which there are many different types, is usually placed between the reaction beds. These devices provide for liquid-liquid, gas-gas, and gas-liquid mixing and for homogenous distribution of the mixed fluids over the next lower reaction bed.

Such fluid mixing devices are known in the art. Known fluid mixing devices, for example from EP 716 881, WO 97/46303, and WO 99/28024.

When the catalyst activity is no longer satisfactory, the catalyst needs to be replaced by fresh or regenerated catalyst. In the particular case of heavier hydrocarbon oils, such as the heavy fractions resulting from vacuum distillation, hydroprocessing generally results in the formation of excessive amounts of coke which causes the catalyst particles to agglomerate forming one solid mass, such that removal of the used catalyst usually requires considerable time and effort. There are known various ways for removing caked catalyst. One method is to provide the support trays with openings through which the catalyst, after having been cut into smaller pieces, can be removed. Reloading the catalyst bed(s) with fresh or regenerated catalyst can subsequently take place via the same openings.

For reasons of cost reduction, time saving, personnel health and safety, it is desired that unloading and reloading of catalyst can be done externally, i.e. without requiring direct entry of personnel into the reactor. It is known in the art, e.g. from EP 679 431, to unload and reload catalyst particles via vertical pipes through the interbed reactor internals, such as a mixing device.

It is advantageous when such a pipe is located along the central longitudinal axis of the reactor vessel, since this minimises the distance between any point of the catalyst bed to be unloaded and the unloading pipe. Moreover, since existing reactor vessels are often provided with a central wide manhole in the top of the vessel, this manhole can be used for drilling and water jetting in case of a central unloading pipe. Thus, a large central pipe through the reactor internals is particularly suitable for external unloading and reloading of catalyst.

A disadvantage of a large central pipe for unloading and reloading of catalyst, however, is that, during normal operation, it will impede the uniform distribution of gas and liquid and of the temperature in the fluids entering the next lower catalyst bed when using the fluid mixing devices known in the art.

It has now been found that very good distribution of gas and liquid can be achieved, also in a reactor having a large central pipe for catalyst unloading, if a mixing device comprising a swirl chamber for mixing liquid is used wherein the swirl chamber is co-axially arranged around the pipe.

Therefore, the present invention relates to a multiple bed downflow reactor comprising vertically spaced apart reaction beds, preferably beds of catalyst particles, and, between adjacent beds, a mixing device for mixing fluids, the mixing device comprising:

-   -   (i) a substantially horizontal collection tray,     -   (ii) a swirl chamber for mixing liquid arranged below the         collection tray, having an upper end part that is in direct         fluid communication with the upper surface of the collection         tray and an outlet opening at its lower end, and     -   (iii) a substantially horizontal distribution tray located below         the swirl chamber, which distribution tray is provided with a         plurality of openings or downcomers for downward flow of liquid         and gas,         in which reactor each reaction bed rests upon a support tray         provided with a central opening and which reactor further         comprises open-ended pipes extending through each central         opening such that a vertical chute is formed from the reaction         bed above the mixing device to the reaction bed below the mixing         device, wherein the swirl chamber of the mixing device is         arranged around the open-ended pipe.

The pipes may have any geometrical shape. Examples include cylindrical, rectangular or conical pipes. The inner diameter of each pipe should be sufficiently large to allow the catalyst pieces formed by hydro jet cutting, cutting with a mechanical drill, or by use of expanding gas cartridges to pass through the pipe and to allow accurate cutting and drilling with known external, i.e. without the need for entry of personnel into the reactor, methods. Suitable inner diameters then, may vary from as small as 20 cm to as large as 1 m. Preferably, the pipes have an inner diameter in the range of from 30 to 75 cm.

The upper end of each pipe may, during normal operation of the reactor, be provided with a removable closure, for example a breakplate such as disclosed in EP 679 431. The advantage of a pipe provided with a removable closure is that, during normal operation, no bypass of gas and liquid through the pipe to the next lower reaction bed occurs.

If the pipes are provided with a closure, each pipe will typically extend from the lower end of a catalyst bed to the distribution tray below that bed or to the upper surface of the next lower catalyst bed. In case of pipes not provided with a closure, the pipe will typically extend from the lower end of a catalyst bed to somewhere in the next lower catalyst bed. In that case, the pipe will, during normal operation of the reactor, typically be filled with a low voidage inert packing, such as ceramic particles. It has been found that an excellent mixing performance over a wide range of gas and liquid loads, typically from as low as 33% to as high as 200% of the normal loads, can be achieved in the reactor according to the invention if the swirl chamber has a certain ratio of length and diameter. For optimal fluid mixing, especially at high turn-down ratios, it is preferred that the swirl chamber has a length that is at least 0.35 times its inner diameter, more preferable at least 0.50 times its inner diameter, even more preferably at least 0.65 times its inner diameter. In order to limit the length of the mixing device and therewith the volume occupied in the reactor, the length will generally not be larger than 1.5 times its inner diameter.

Reference herein to the length of the swirl chamber is to the vertical distance between the lower point of its inlet or inlets and its outlet opening. In the case of a polygonal swirl chamber, reference herein to its inner diameter is to the largest cross-sectional distance between opposite side walls through the central axis of the chamber.

The reactor according to the invention may comprise one or more swirl chambers in addition to the one arranged around the central pipe.

The substantial horizontal collection tray of the mixing device may be curved or conical, provided that the upper end part of the swirl chamber is in direct fluid communication with the upper surface of the lowest point of the collection tray. Reference herein to a substantial horizontal tray is to a tray having its symmetry axis perpendicular to the horizontal plane. Preferably, the collection tray is flat.

Preferably, the collection tray is further provided with means for passage of gas, preferably in the form of at least one downcomer extending through the collection tray, the downcomer(s) being provided with a gas inlet opening located above the collection tray and a gas outlet opening located at the level of the lower surface of or below the collection tray. The downcomer(s) is/are preferably provided with a fluid deflector plate located above the gas inlet opening. The gas outlet opening may be axial or radial. Preferably, the downcomer has a radial outlet opening in combination with a curved plate that directs the gas to the radial outlet opening in order to minimise pressure drop.

The mixing device may further comprise means for distributing a quench fluid located above the collecting tray, in order to achieve cooling of effluent between the reaction beds of a multiple-bed downflow reactor. Means for distributing a quench fluid are well known in the art and are described, for example, in EP 427 733, U.S. Pat. No. 3,787,189 and U.S. Pat. No. 3,855,068.

The mixing device has a distribution tray below the outlet opening of the swirl chamber for evenly distributing gas and liquid before the fluids enter a lower reaction bed. Suitable distribution trays are known in the art, for example from EP 716 881, EP 715 544, and U.S. Pat. No. 5,989,502. A preferred distribution tray is the one disclosed in EP 716 881.

The mixing device may further comprise a substantially horizontal pre-distribution tray arranged between the swirl chamber and the distribution tray. Such pre-distribution trays are known in the art. The pre-distribution tray may be round, square or rectangular in shape and has preferably a diameter that is smaller than the diameter of the distribution tray. Preferably, the pre-distribution tray is provided with an overflow weir at its perimeter. The tray is provided with a plurality of openings, preferably located near its perimeter. The advantages of having a pre-distribution tray are that it enables liquid to be spread more evenly over the distribution tray and it helps to promote liquid-liquid interactions and thus liquid equilibration.

The reactor according to the invention has at least one inlet for gas and/or liquid, at least one outlet for reactor effluent and at least two consecutive reaction beds, typically beds of catalyst particles, each bed resting upon a support tray. The construction of suitable support trays is known in the art. For instance, commonly applied support trays comprise one or more permeable plates such as sieve plates supported by support beams, whereby the catalyst bed rests upon the said permeable plates. Gaseous and liquid products formed in the reactions occurring in the catalyst bed are passed through the permeable plates to the subsequent catalyst bed or reactor outlet. Such reactors are typically used in the hydroprocessing of hydrocarbon oils.

In a further aspect, the invention relates to the use of a multiple bed downflow reactor as hereinbefore defined in hydrocarbon processing, preferably in catalytic dewaxing, hydrotreating, hydrocracking, or hydrodesulphurisation.

The reactor according to the invention will now be illustrated by way of example by means of schematic FIGS. 1 and 2.

FIG. 1 is a longitudinal section of part of a reactor according to the invention.

FIG. 2 shows a longitudinal section of the downcomer for gas of the mixing device shown in FIG. 1, the section being through line II—II in the plane perpendicular to the plane of the drawing of FIG. 1.

In FIG. 1 is shown part of the side wall 1 and two adjacent catalyst beds 2 a and 2 b of a multiple-bed reactor. The catalyst beds 2 a and 2 b are supported on sieve plate 3, supported by support beams (not shown). A mixing device 5 is positioned between catalyst beds 2 a and 2 b. The mixing device 5 comprises a flat, horizontal collection tray 6 and a swirl chamber 7 arranged below the collection tray 6. The swirl chamber 7 has four inlet nozzles 28 (only two inlet nozzles shown) that are in direct fluid communication with the upper surface 9 of collection tray 6. The chamber is further provided with vanes 29 near its annular outlet 10 and means 11 for imposing a swirling action on the liquid passing through it. The mixing device 5 comprises means for passage of gas in the form of three downcomers for gas 12 (only one downcomer shown) extending through the collection tray 6. A distribution tray 13 provided with a plurality of downcomers 14 is located below swirl chamber 7 and a pre-distribution tray 15 comprising an overflow weir 16 and a plurality of openings 17 is located between swirl chamber 7 and distribution tray 15. The mixing device further comprises a quench ring 18.

The reactor comprises a large central open-ended pipe 23 forming a vertical chute 24 from catalyst bed 2 a to underlying catalyst bed 2 b for unloading and reloading of catalyst. The sieve plate 3 upon which catalyst bed 2 a rests, is provided with a central opening 25 through which open-ended pipe 23 extends. The pipe 23 also extends through mixing device 5. The swirl chamber 7 is co-axially arranged around pipe 23. At its upper end, pipe 23 is closed by breakplate 26. In the embodiment shown in FIG. 1, the upper end of pipe 23 is located above the upper surface of sieve plate 3 on which catalyst bed 2 a rests. In that case, the part of the reaction bed that is below the upper end of pipe 23 is filled with an inert support material, for example a layer 27 of ceramic particles. The catalyst bed 2 a is then positioned upon the layer 27 of inert support material.

During normal operation of the mixing device shown in FIG. 1, effluent from catalyst bed 2 a is cooled by quench fluid from quench ring 18. The liquid effluent is collected on collection tray 6 and enters swirl chamber 7 through its inlet nozzles 28. In the swirling chamber 7, a swirling movement is imposed on the liquid by swirling means 11. Suitable means for imposing a swirling action on fluids are known in the art, for example a tangential inlet opening, swirling vanes or baffles attached to the inner surface of the side wall of the swirl chamber or the like. The combination of a swirling action imposed on the liquid and the length of the swirling chamber result in excellent liquid-liquid mixing over a wide range of liquid and gas throughput. It is an advantage of the mixing device according to the invention that the degree of liquid-liquid mixing achieved in swirl chamber 7 is practically independent of the gas load. The mixed liquid leaves the swirl chamber 7 via outlet opening 10. Preferably, the swirling chamber 7 is provided with vanes 29 or the like near the outlet opening 10 to stop the swirling movement of the liquid and thus increasing turbulence and further improving liquid-liquid mixing.

Effluent gas from catalyst bed 2 a passes collection tray 6 via downcomers for gas 12. Part of the effluent gas may pass collection tray 6 via swirl chamber 7. It will be appreciated that it will inter alia depend on the gas and liquid loads and on the size, shape and location of the inlet(s) of the swirl chamber and the gas inlet opening(s) of the means for passage of gas, what part of the effluent gas will pass through the means for gas passage and what part through the swirl chamber.

Alternatively, the reactor according to the invention does not comprise separate means for passage for gas, in which case all effluent gas will pass the collection tray via the swirl chamber.

In the mixing device according to the invention, gas-gas mixing is effected upon quenching and upon passage of gas through the downcomers for gas 12 and/or swirl chamber 7.

The liquid leaving swirl chamber 7 accumulates on pre-distribution tray 15, where it passes downwardly to distribution tray 13 beneath through openings 17 or, sometimes, by breaching the overflow weir 16. Gas is deflected by the pre-distribution tray 15 and flows to the distribution tray 13.

At the distribution tray 13, equilibrated gas and liquid phases are brought together. The distribution tray 13 serves two purposes. Firstly, it evenly distributes liquid and gas before the fluids enter a lower reaction bed 2 b and, secondly, it allows contact between liquid and gas to provide liquid-gas interaction.

In FIG. 2, one of the downcomers for gas 12 of FIG. 1 is shown in greater detail. The downcomer 12 has a gas inlet opening 19 located above collection tray 6, a radial gas outlet opening 20, located below collection tray 6, a fluid deflector plate 21 located above gas inlet opening 19, and a curved plate 22 to direct the gas that passes through the downcomer to radial outlet opening 20. 

1. A multiple bed downflow reactor comprising vertically spaced apart reaction beds, and between the adjacent beds, a mixing device for mixing fluids, the mixing device comprising: (i) a substantially horizontal collection tray, (ii) a swirl chamber for mixing liquid arranged below the collection tray, having an upper end part that is in direct fluid communication with the upper surface of the collection tray and an outlet opening at its lower end, and (iii) a substantially horizontal distribution tray located below the swirl chamber, which distribution tray is provided with a plurality of openings or downcomers for downward flow of liquid and gas, in which reactor each reaction bed rests upon a support tray provided with a central opening and which reactor further comprises open-ended pipes extending through each central opening such that a vertical chute is formed from the reaction bed above the mixing device to the reaction bed below the mixing device, wherein the swirl chamber of the mixing device is arranged around the open-ended pipe.
 2. The reactor according to claim 1, wherein, during normal operation, the upper end of the pipe is provided with a removable closure.
 3. The reactor according to claim 2, wherein the swirl chamber has a length that is at least 0.35 times its inner diameter.
 4. The reactor according claim 2, wherein the collection tray is further provided with means for passage of gas, said means for passage of gas comprises at least one downcomer extending through the collection tray, the downcomer(s) being provided with a gas inlet opening located above the collection tray and a gas outlet opening located at the level of the lower surface of or below the collection tray.
 5. The reactor according to claim 2, which further comprises means for distributing a quench fluid, the means being located above the collection tray.
 6. The reactor according to claim 2, which further comprises a substantially horizontal pre-distribution tray arranged between the swirl chamber and the distribution tray.
 7. The reactor according to claim 3, wherein the collection tray is further provided with means for passage of gas, said means for passage of gas comprises at least one downcomer extending through the collection tray, the downcomer(s) being provided with a gas inlet opening located above the collection tray and a gas outlet opening located at the level of the lower surface of or below the collection tray.
 8. The reactor according to claim 3, which further comprises means for distributing a quench fluid, the means being located above the collection tray.
 9. The reactor according to claim 3, which further comprises a substantially horizontal pre-distribution tray arranged between the swirl chamber and the distribution tray.
 10. The reactor according to claim 7, which further comprises means for distributing a quench fluid, the means being located above the collection tray.
 11. The reactor according to claim 7, which further comprises a substantially horizontal pre-distribution tray arranged between the swirl chamber and the distribution tray.
 12. The reactor according to claim 10, which further comprises a substantially horizontal pre-distribution tray arranged between the swirl chamber and the distribution tray.
 13. The reactor according to claim 1, wherein the swirl chamber has a length that is at least 0.35 times its inner diameter.
 14. The reactor according claim 1, wherein the collection tray is further provided with means for passage of gas, said means for passage of gas comprises at least one downcomer extending through the collection tray, the downcomer(s) being provided with a gas inlet opening located above the collection tray and a gas outlet opening located at the level of the lower surface of or below the collection tray.
 15. The reactor according to claim 1, which further comprises means for distributing a quench fluid, the means being located above the collection tray.
 16. The reactor according to claim 1, which further comprises a substantially horizontal pre-distribution tray arranged between the swirl chamber and the distribution tray. 